Metal Cutting

Material removal through cutting, turning, milling, drilling, grinding, tapping and more using machinery such as laser cutting systems, plasma cutting systems, oxyfuel cutting systems, milling machines, drill presses, lathes, horizontal machining centers, vertical machining centers, turning centers, multitasking machines, electrical discharge machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

Turning Powdered Metal Into Profit

Check out how this Ohio machine shop mastered the machining of very high quantities of powdered metal automotive components that cause excessive tool wear and require constant offset adjustments.

Internet 4.0 Innovations for Machine Tools

Using an integrated Beckhoff control computer, the 701S micromachining center from Willemin-Macodel delivers path accuracy better than 0.2 μm, low sensitivity to temperature fluctuations and very high precision and repeatability at a maximum speed of 80,000 rpm – without tool holders, which increases static and dynamic rigidity and results in very high balancing quality and a low radial runout (less than 1 μm at the tool tip).
Take a look at how PC-based control technology is turning visionary Industry 4.0 concepts into profitable "smart factories" through the use of Google Glass in automation, all-in-one robot and machine tool control, and standard OPC UA connectivity.
CAD/CAM Software

Mission Accomplished

Robotic metal polishing; Mico Industries.
Thanks to SolidCAM iMachining, cycle times are down 50 percent, tool life is up 40 percent, and Mico Industries is creating dies, weld fixtures and check fixtures without compromise.
Drilling Machines

Making Natural Gas Clean with a “Hole” Lot of Pressure

A pressure vessel in the mid-fabrication stages. The pressure vessels Mueller Environmental manufacturers measure anywhere from 4 ft to 8 ft in diameter and are made from ½ in to 3 1/2 in thick 5617 rolled steel plate. The diameter and material thickness depends upon the pressure the vessel must withstand. Sometimes pressures can reach as high as 3,000 psi.
Using a modified HMD915 magnetic drill and Industrial Series of Rotabroach Cutters from Hougen enabled Mueller Environmental to cost-effectively develop a patented new system for cleaning natural gas.
Gear Cutting Machines

Gear Production: Higher Speed, Closer Precision

The accuracy of the Fast Gear Alignment function eliminates the need to acquire acoustic signatures during dressing or grinding. Aligning a grinding wheel with a 180 mm diameter gear with 71 helical teeth takes just 0.5 of a second – without any need to acquire acoustic signatures or make manual adjustments. 
Automated threaded wheel grinding on gear production machines has now been boosted by an order of magnitude with increased machining accuracy to DIN class 3.
Grinding Machines

Gear Hobbers and Control Migration

All seven axes on the 400H Series II gear hobber, including the 560 Nm work piece spindle motor, are controlled by NUMDrive C servo drives and a Flexium 68 CNC system. (first view)
This is the story of how Bourn & Koch upgraded its older gear hobbers to advanced CNC systems to machine large bull and cluster gears, worms, shafts, splines and pinions for the defense and aerospace, oil/gas drilling, mining, heavy equipment and power generation industries.
Honing Machines

A Chip Off the Old Block

Dart produces about 16,000 cylinder heads per year.
Dart masters the "peaks and valleys" of custom engine block production with an advanced American-made Sunnen SV-20 flexible honing system that uses programmable control to replicate “best” engine parameters and produce expert results with minimal operator expertise.
Horizontal Machining Centers

Horizontal Machining vs. Vertical Machining: Rethinking Your Operation

A horizontal machining center provides additional access to the part. Since multiple faces of a workpiece can be machined in a single setup, a part that takes six operations on a vertical machine can be completed in just two on a horizontal. This means better quality parts, reduced setups, handling and machining time – all of which are ideal for low-volume, repeat work.  
If the manufacturer is able to move past the sticker price and examine the dollars spent making the part, or the cost per part, a multitude of qualities can factor into the machine tool’s return on investment. Here are some reasons why a less expensive piece of equipment is not always the obvious choice.
Laser Cutting

Micromachining: No More Constraints

Prototyping time for new nozzle designs is reduced from weeks in the machine shop to 24 hours with the R-Drill, dramatically accelerating design optimization and time to market. The R-Drill reduces drilling time by approximately 30 percent while increasing yield to nearly 100 percent, with no need for expensive post-processing to correct HAZ damage.
The latest femtosecond laser technology from Raydiance can reduce cost per part by 20 percent to 50 percent and reduce product design, prototyping and development from months to as little as 24 hours.

Hard Thread Turning Shortens The Process Chain

Figure 1. High rigidity allows higher process forces: Hembrug turning machines are especially suitable for high-precision hard turning.
High precision hard turning techniques are enjoying ever greater popularity in the metal processing industry. By shortening cycle times and increasing flexibility, high precision hard turning has advantages over grinding in particular when it comes to processing complicated parts such as spindle nuts or threaded spindles in the hard state.
Machine Controls

Next Generation Grinding Technology

The shop uses CNC gear inspection equipment and coordinate measuring machines to monitor lot runs up to 500 pieces in 4140, 4150 and 8620 steel bar, forgings, and cast and ductile iron, brass, bronze and aluminum. Typical parts include helical and spur gears up to 30 in diameter, splined shafts up to 54 in long, and large CNC machined coomponents.  (first view)
Take a look at how this gear specialist and machine shop used new Swiss grinding technology with an advanced CNC to cut their cycle time on one gear from 40 minutes down to six minutes.
Milling Machines

Boring Mill Fuels Energy Sector Expansion for Machine Shop

The dual-pallet, rotary table Giddings & Lewis MC 1600 horizontal boring mill (HBM) from Fives is designed for multi-axis contour milling, precision boring, drilling and tapping. It will produce a variety of large parts for Milwaukee Machine Works, including wind turbine gearbox housings and fluid end manifolds for the oil/gas industry.
Milwaukee Machine Works expands its energy sector business into wind turbine gearbox housings, fluid end manifolds for the oil/gas industry, and other oversized components up to 10 ft long and weighing up to 7,000 lb with a new large capacity dual-pallet Giddings & Lewis MC 1600 from Fives.
Multitasking Machines

Shoot from the Hip

Custom shoulder implant parts on the NTX 2000 turn-mill center, which has opened up new possibilities for parts that previously required at least two operations. Rasp handles that were previously contracted outside will become some of the first components loaded on the new machine.
This orthopedics manufacturer achieves one hit machining in an automated lights-out environment using advanced turn-mill machines that take their custom implants for coated hip replacement to a whole new efficiency.
Ram EDM Machines

A Hole New Game: Precision EDM Holemaking Goes Smaller, Deeper and Faster

Technically advanced EDM drill systems merge hole popper technology with die-sinker digital generator technology for more precise spark control that essentially puts the holemaking accuracy in the technological hands of the machine tool.
While hole-popper systems are quite capable of generating very small accurate holes with good surface quality, advanced EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality.

How to Simplify Complex Geometry Tool Repair

By enabling the entry point of the grinding wheel to follow the corner radius of the cutting edge, the software now facilitates the grinding of a defined rake angle on complex body forms and on cutting edges which pass from the body of the tool to its tip – a task that was previously extremely difficult to achieve.
A new release of NUMROTO tool grinding software meets the growing challenges of grinding and servicing new generations of complex geometry drills and end mills.
Vertical Machining Centers

Advanced Machining Allows Subsea Valves To Handle the Pressure

Operating a DMG / Mori Seiki NL2500 at BEL Valves.
BEL Valves uses a variety of DMG / MORI SEIKI machine tools to meet its paramount need for reliability during production. 
Wire EDM Machines

Wire Changing EDM Proves Big in Micro Tooling Production

Mike (right) and Eric Blackwell of Scenic Tool and Stamping rely on a CUT 2000 wire EDM from GF AgieCharmilles that uses new third-generation twin-head automatic wire changing to easily achieve surface finishes of .2 Ra. (Click on photo to enlarge it)
As consumer products continue to shrink in size, die shops such as Scenic Tool and Stamping face the challenge of developing highly intricate tooling for stamping the tiny components that make up miniature merchandise. As a result, an increasing number of these shops are incorporating high-precision wire EDMs like the Cut 2000 from GF AgieCharmilles that provide automatic wire-changing capability. uses the to easily switch wires of different sizes and materials.
Metal Cutting: Products

Tool Grinder Handles Complex Cutting Tools

The U Grind has a NUM Fleximum control with the latest generation of NUMROTOplus tool grinding software for all types of cutting tools, including complex step/form tools, hobs, burs, shape cutters, T-slot cutters, high performance endmills and drills, routers, form tools, porting tools and more.
The flexible, high-accuracy U-Grind 5-axis CNC tool grinder from Strausak is ideal for small batch production, regrinding, and high-precision tool grinding.

Sealed Computer Keyboard for Machine Shops

The Really O'Cool keyboard is great for machine shops, production lines, part manufacturing or metalworking where oils, dirt or water is a problem. 
The Really O’Cool oil-resistant keyboard from Man & Machine is tough enough to stand up in heavy-duty metal fabrication environments where oils, dirt or water is a problem.

PCD Chipbreaker for Machining Aluminum

With cutting speeds from 800 m/min to 2,500 m/min and feed rates from 0.1 mm/r to 0.3 mm/r depth of cut, the Type IS chipbreaker from Lach Diamond can achieve a maximum utilization of the cutting width from to 3 mm to 5 mm.
The Type IS chipbreaker from Lach Diamond is ideal for rough machining thick-walled, solid components and for interrupted cuts.